Protective shield to prevent shorting in polymer battery

ABSTRACT

A Li-ion and/or Li-ion polymer cell, comprised of a first cathode section and a second cathode section. Each cathode section has a cathode current collector in contact therewith. The cathode current collector is comprised of a sheet of metal mesh having a tab portion that extends outwardly from the sheet beyond the cathode section. The cathode tab from the first cathode section is disposed adjacent to the cathode tab from the second cathode section. An anode section is disposed between the cathode sections. The anode section has an anode current collector having a tab portion that extends therefrom beyond the anode section. A separator layer is disposed between the anode section and each of the cathode sections. A protective band is disposed between the tabs of each cathode current collector. The protective band is disposed between the cathode tabs and the anode section to prevent shorts when the cathode tabs are pressed together to form a single positive lead.

FIELD OF THE INVENTION

The present invention relates generally to Li-ion and/or Li-ion polymer batteries, and more particularly, to a Li-ion and/or Li-ion polymer battery having shielded leads to reduce the likelihood of shorting.

BACKGROUND OF THE INVENTION

Broadly stated, a Li-ion and/or Li-ion polymer cell is generally comprised of an anode section, a cathode section and a separator layer that is disposed between the anode section and the cathode section. A layer of a first conductive material is disposed within or in contact with the anode section. This layer forms what is conventionally referred to as an “anode current collector.” A second layer of a conductive material is disposed within or in contact to the cathode section to form a “cathode current collector.” It is conventionally known to use metal screens, meshes or foils to form the aforementioned current collectors. Typically, a copper mesh is used to form the anode current collector, and an aluminum metal mesh is used to form the cathode current collector. Current collectors are typically die-cut from sheets of metal mesh, and each current collector includes a tab portion that defines a battery lead. In this respect, an anode current collector will include a tab to define a battery's negative lead and the cathode current collector will include a tab to define a battery's positive lead.

A problem with using metal mesh as a current collector is that metal burrs or shards may be formed during the die-cutting process. These burrs or shards project at angles to the plane of the current collector. In the body of the cell, these burrs or shards generally do not create a problem as the layers of metal mesh forming the respective current collectors are separately maintained from each other by the respective layers of material forming the cell. However, the tabs forming the electrical leads extend beyond the peripheries of the anode section, cathode section and separator layers and do create a problem of shorting, particularly in a cell having two or more cathodes. In such cells, the leads of the cathode current collectors are typically in registry with each other and are pressed together to form one positive battery lead. Specifically, the aforementioned cells are enclosed within a housing or packaging. During the fabrication process, the packaging is usually sealed along the peripheral edges of the cell, thereby forcing like leads together. In most battery designs opposite leads are offset from each other so that they will not contact each other. Like leads, such as two cathode sections, are typically forced together and joined. It is at these locations where the burrs or shards are more likely to penetrate through the separator layers and short circuit the cell by coming into contact with layers of the opposite polarity.

The present invention overcomes this problem by providing a protective band on the leads of the current collector where the leads extend from the cell to prevent burrs or shards on the current collectors from penetrating through the separator layer.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a Li-ion and/or Li-ion polymer cell, comprised of two cathode sections and an anode section disposed between the cathode sections. A separator layer is disposed between the anode section and each of the cathode sections. A first, planar metal mesh layer is disposed within the anode section. The first metal mesh layer has a coplanar tab extending beyond the separator layer to define a negative lead. A second, planar metal mesh layer is disposed within each cathode section. The second metal mesh layer has a coplanar tab extending beyond each separator layer to form a positive lead. A protective band is applied on the anode section disposed between the cathode tabs where the cathode tabs extend beyond the cathode sections.

In accordance with another aspect of the present invention, there is provided a Li-ion and/or Li-ion polymer cell, comprised of a first cathode section and a second cathode section. Each cathode section has a cathode current collector in contact therewith. The cathode current collector is comprised of a sheet of metal mesh having a tab portion that extends outwardly from the sheet beyond the cathode section to form a cathode section lead. The cathode section lead from the first cathode section is disposed adjacent to the cathode section lead from the second cathode section. An anode section is disposed between the cathode sections. The anode section has an anode current collector having a tab portion that extends therefrom beyond the anode section to form an anode section lead. A separator layer is disposed between the anode section and each of the cathode sections. A protective band is disposed between the tab portion of each cathode current collector where the tab portion extends from the sheet. The protective bands are disposed between the tab portions to prevent shorts when the tab portions are pressed together to form a single positive lead.

In accordance with another aspect of the present invention, there is provided a Li-ion and/or Li-ion polymer cell, comprised of two anode sections and a cathode section disposed between the anode sections. A separator layer is disposed between the cathode section and each of the anode sections. A first, planar metal mesh layer is disposed within each of the anode sections. The first metal mesh layer has a coplanar tab extending beyond the separator layer to define a negative lead. A second, planar metal mesh layer is disposed within the cathode section. The second metal mesh layer has a coplanar tab extending beyond the separator layer to form a positive lead. A protective band is applied on the cathode section disposed between the anode tabs where the tabs extend beyond the anode sections.

It is an object of the present invention to provide a Li-ion and/or Li-ion polymer cell using metal mesh as current collectors.

It is another object of the present invention to provide a cell as described above that is less susceptible to failure from short-circuiting during fabrication.

Another object of the present invention is to provide a cell as described above having protective sleeves around the battery leads in the vicinity where the leads extend from the cell.

A still further object of the present invention is to provide a cell as described above having a protective tape disposed between adjacent leads to isolate the leads from each other and from other battery components.

These and other objects and advantages will become apparent from the following description of a preferred embodiment of the invention, taken together with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:

FIG. 1 is a perspective view of a cell illustrating a preferred embodiment of the present invention;

FIG. 2 is a perspective view of an anode section from the cell shown in FIG. 1, showing a protective band thereon;

FIG. 3 is a partially broken away, top plan view of the cell shown in FIG. 1;

FIG. 4 is a partially broken away, front elevational view of the cell shown in FIG. 1; and

FIG. 5 is a partial, sectional view taken along lines 5—5 of FIG. 4.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

Referring now to the drawings wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting same, FIG. 1 shows a battery 10 illustrating a preferred embodiment of the present invention. (In the drawings, the respective parts and components in many instances are not drawn to scale and, in some instances, are exaggerated for the purposes of illustration). Battery 10 is formed of a polymer, electrolytic cell 12 contained within a package 14 (shown in phantom in the drawings) that is formed of a flexible laminate material. Cell 12 is preferably a lithium-based electrochemical cell. Cell 12 may be a primary (non-rechargeable) cell or a secondary (rechargeable) cell.

In the embodiment shown, cell 12 is a “bi-cell” comprised of two cathode sections 22 and an anode section 32. Each cathode section 22 is comprised of two layers 24 of a cathode film. The film-forming cathode layer 24 is preferably comprised of a lithiated metal oxide active material, a conductive material and a binder material. A current collector 26 formed of a metal screen or mesh is provided between each cathode layer 24. Each current collector 26 includes an outward extending tab or strip 28.

Anode section 32 is comprised of two layers of an anode film having a current collector 36 disposed therebetween. The film-forming anode layers 34 are preferably comprised of a carbon active material, a conductive material and a binder material. Current collector 36 includes an outward extending tab or strip 38 that defines the negative lead of battery 10.

Between anode section 32 and each cathode section 22, a separator film 42 is disposed. Separator film layer 42 is preferably formed of a polymeric matrix containing an ionically conductive electrolyte.

Each cathode layer 24 preferably has a thickness of about 50 μm to about 300 μm, preferably about 100 μm to about 200 μm. Each anode layer 34 has a thickness of about 50 μm to about 300 μm, preferably about 100 μm to about 200 μm. Each separator layer 42 has a thickness of about 10 μm to about 75 μm, preferably about 15 μm to about 35 μm. Current collectors 26, 36 are preferably formed of a metal mesh or screen having a thickness of about 25 μm to about 50 μm. The overall thickness of cell 12 is about 800 μm or less, and preferably about 500 μm or less.

As illustrated in FIG. 1, strips 28 of cathode current collectors 26 are disposed in registry with each other to be joined together to define a single positive lead of battery 10. In accordance with the present invention, a protective band 50 is wrapped over the edge of anode section 32. Band 50 is disposed on anode section 32 to be in registry with, i.e., disposed between, cathode tabs 28, as best seen in FIGS. 3 and 4. As best seen in FIGS. 3 and 4, protective band 50 is dimensioned to extend beyond both edges of cathode tabs 28 to insure cathode tabs 28 are isolated from anode section 32 when cathode sections 22 and anode section 32 are assembled together to form cell 10. Protective band 50 may be formed of two separate strips of material applied to the opposite sides of anode section 32, but more preferably is comprised of a single strip of material that is wrapped over the edge of anode section 32, as illustrated in FIGS. 1-5.

In accordance with the present invention, protective band 50 is comprised of an outer polymer layer 52 and an inner adhesive layer 54. Outer layer 52 is preferably formed of a tough, thin polymer material having high dielectric properties and that is inert to the components forming cell 12. Various plastic tapes find advantageous application in forming outer layer 52. Such plastic materials may include polyimide, polyester and the like. Polymeric outer layer 52 preferably has a thickness of about 0.0005 inches to about 0.0015 inches.

Adhesive layer 54 is preferably formed of a non-conductive, thermosetting polymer, sealing material. An adhesive material, such as silicone, finds advantageous use as adhesive layer 54 in that this material is stable in the environment of a lithium ion polymer battery. Other adhesive materials such as rubber or resin may also be used. The thickness of adhesive layer 54 is about 0.001 inches to about 0.002 inches. The total thickness of protective band 50 is preferably about 0.0015 inches to about 0.0030 inches.

In accordance with the present invention, protective band 50 may be applied manually or by automatic or semi-automatic operations. In this respect, protective band 50 is preferably applied to anode section 32 prior to its assembly in cell 12.

The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purposes of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. For example, cell 12 as heretofore described, includes a cathode section 22 and an anode section 32 formed from layers of generally solid material. It shall be appreciated by those skilled in the art that cathode sections 22 may be formed of a single layer of a viscous material having cathode current collectors embedded therein. Likewise, anode section 32 may be formed of a single layer of a viscous material having anode current collector 36 embedded therein. Still further, battery 10 may be formed of two anode sections with a cathode section disposed therebetween, wherein protective band 50 is wrapped over the edge of the cathode section between the tabs of the anode sections. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof. 

Having described the invention, the following is claimed:
 1. A Li-ion cell, comprised of two cathode sections; an anode section disposed between said cathode sections; a separator layer disposed between said anode section and each of said cathode sections; a first, planar metal mesh layer within said anode section, said first metal mesh layer having a coplanar tab extending beyond said separator layer to define a negative lead; a second, planar metal mesh layer within said cathode section, said second metal mesh layer having a coplanar tab extending beyond said separator layer to form a positive lead; a single protective band applied on over an edge of said anode section, said band disposed between said cathode tabs where said tabs extend beyond said cathode sections and being dimensioned to extend beyond both edges of said cathode tabs.
 2. A Li-ion cell as defined in claim 1, wherein said protective band is comprised of an outer polymer layer and an inner adhesive layer.
 3. A Li-ion cell as defined in claim 2, wherein said polymer layer has a thickness between about 0.0005 inches and about 0.0015 inches.
 4. A Li-ion cell as defined in claim 3, wherein said outer polymer layer is comprised of polyimide.
 5. A Li-ion cell as defined in claim 3, wherein said outer polymer layer is comprised of polyester.
 6. A Li-ion cell as defined in claim 2, wherein said adhesive layer is comprised of silicone.
 7. A Li-ion cell as defined in claim 6, wherein said adhesive layer has a thickness between about 0.001 inches and about 0.003 inches.
 8. A Li-ion cell as defined in claim 3, wherein each of said protective bands has a thickness between about 0.0015 inches and about 0.003 inches.
 9. A Li-ion cell, comprised of: a first cathode section and a second cathode section, each cathode section having a cathode current collector in contact therewith, said cathode current collector comprised of a sheet of metal mesh having a tab portion extending outwardly from said sheet beyond said cathode section to form a cathode section lead, said cathode section lead from said first cathode section being disposed adjacent to said cathode section lead from said second cathode section; an anode section disposed between said cathode sections, said anode section having an anode current collector having a tab portion extending therefrom beyond said anode section to form an anode section lead; a separator layer disposed between said anode section and each of said cathode sections; and a single protective band applied over an edge of said anode section between said cathode tab portions, said protective band disposed between said cathode tab portions, and being dimensioned to extend beyond both edges of said cathode tabs to prevent shorts when said cathode tab portions are pressed together to form a single positive lead.
 10. A Li-ion cell as defined in claim 9, wherein said protective band is comprised of an outer polymer layer and an inner adhesive layer.
 11. A Li-ion cell as defined in claim 10, wherein said polymer layer has a thickness between about 0.0005 inches and about 0.0015 inches.
 12. A Li-ion cell as defined in claim 11, wherein said outer polymer layer is comprised of polyimide.
 13. A Li-ion cell as defined in claim 11, wherein said outer polymer layer is comprised of polyester.
 14. A Li-ion cell as defined in claim 9, wherein said adhesive layer has a thickness between about 0.001 inches and about 0.003 inches.
 15. A Li-ion cell as defined in claim 14, wherein said adhesive layer is comprised of silicone.
 16. A Li-ion cell as defined in claim 9, wherein each of said protective bands has a thickness between about 0.0015 inches and about 0.003 inches.
 17. A Li-ion cell, comprised of: two anode sections; a cathode section disposed between said anode sections; a separator layer disposed between said cathode section and each of said anode sections; a first, planar metal mesh layer within each of said anode sections, said first metal mesh layer having a coplanar tab extending beyond said separator layer to define a negative lead; a second, planar metal mesh layer within said cathode section, said second metal mesh layer having a coplanar tab extending beyond said separator layer to form a positive lead; a single protective band applied over an edge of said cathode section, said band disposed between said anode tabs where said tabs extend beyond said anode sections, and being dimensioned to extend beyond both edges of said cathode tabs.
 18. A Li-ion cell as defined in claim 17, wherein said protective band is comprised of an outer polymer layer and an inner adhesive layer.
 19. A Li-ion cell as defined in claim 18, wherein said outer polymer layer is comprised of polyimide.
 20. A Li-ion cell as defined in claim 18, wherein said outer polymer layer is comprised of polyester.
 21. A Li-ion cell as defined in claim 18, wherein said adhesive layer is comprised of silicone. 